A Study On Quality Control And Improvement Of MLCC Casting Ceramic Film In GH Company

Products quality plays a significant position in the long-term survival of enterprise withthe social development and the intense market competition. Therefore, it is critical to controland improve products quality for the enterprise development.The leading product of GH Company is Multi-layers Ceramic Capacitor (MLCC). Itsmanufacturing process is long and complicated, so it is difficult to control quality.Additionally, because of overcapacity, the whole MLCC market presented as buyer’s market;and for the sellers, sale means the comprehensive competition of price, quality, delivery andservice. However, the abnormal products quality will lead to cost increasing, order loss, andcredibility decline. Thus, it is necessary to take action for company development andperformance growth to improve the competitiveness of product quality.The development direction of the current major MLCC manufacturers trend to thesophisticated gradually: smaller size, larger capacitance, thinner ceramic body, higherwithstand voltage performance, etc. No matter single direction or compound of multipledirections, the quality control of dielectric (casting ceramic film) used for manufacturingMLCC. Meanwhile, the four electrical performance parameters of MLCC are capacitance,dissipation factor, withstand voltage and insulation resistance. Per the DFMA analysis, thefactors affecting the four electrical performance parameters are all related to the quality ofcasting ceramic film. With the attempt to improve the product competitiveness and quality,this thesis chooses A Study on Quality Control and Improvement of MLCC Casting CeramicFilm in GH Company as topic to study. By improving the quality of casting ceramic film, thegoal improving process capability and product performance will be achieved.Aiming at the quality control and improvement study of casting ceramic film, Aiming atthe quality control and improvement of casting ceramic film, the author mainly uses PDCAsteps and decision-making method based on the fact, which is one of the eight qualitymanagement principles, to study. The author analyzes and studies on the quality control forceramic film of representative product0402X104(the film thickness is5um), and per the filmthickness single value X-MR control chart analysis, the film weight process capacity is0.951, which is low. And the author analyzes electrical performance, inner structure and dimension, mainly showing as breakdown, unqualified dimension and low CPK. Then theauthor analyzes per systematic PFMEA, and finds out the possible failure mode of qualitycontrol during casting. From the Risk Priority Number (RPN), the failure modes duringcasting process are film weight and film appearance. Analyzing unqualified film weight percause-effect diagram and systematically analyzing breakdown, the author finds out the mainreasons and formulates related measures and makes improvement. After improvement, finally,the validation result shows that the film quality can be effectively controlled, the processcapability of film weight can be increased to1.718, product quality can be improved andqualified rate can be increased.